Manual Vibration Switch 440 450 Rev f

7/30/2019 Manual Vibration Switch 440 450 Rev f

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ME_90018-031_ RevF_0809

MODEL 440 & 450

ELECTRONIC VIBRATION SWITCH

Installation Manual 90018-031

8824 Fallbrook Dr.Houston, TX 77064, USA

Tel: 1-281-940-1802After Hours Technical Assistance: 1-713-702-8805

Fax: 1-713-559-9421E-mail: [email protected]

www.metrix1.com

Revision: F


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INDEX

Section 1.0 General Description1.1 Introduction1.2 Protection of Rotating and Reciprocating Machinery1.3 Summary of Capabilities1.4 Panel Controls1.5 Specifications

1.6 Safety Warning

Section 2.0 Mechanical Installation2.1 Orientation2.2 Mounting Surface2.3 Temperature Considerations2.4 Cable/Wire2.5 Sealing Outline Drawings

Section 3.0 Electrical Installation3.1 Wiring to the Vibration Switch

3.1.1 AC Power3.1.2 Shutdown Circuit3.1.3 Remote Reset3.1.4 Lockout Option3.1.5 4-20 mA Output3.1.6 Alarm Circuits

3.2 Functional Description and Installation Considerations3.2.1 Alarm or Shutdown3.2.1.1 Units with Triacs3.2.1.2 Units with Analog Switch3.2.2 Open/Close on Alarm3.2.3.1 Auto reset Mode3.2.3.2 Latch Mode3.2.3.3 Remote Reset Mode3.2.4 20 Second Lockout Option

3.2.5 4-20 mA Output

3.3 Special Considerations3.3.1 Light Loads3.3.2 DC Applications3.3.3 120 mA Analog Switch Option Wiring Diagram

Section 4.0 Control Settings 4.1 Setting Trip Points4.2 Setting of Time Delay4.3 Test Mode4.4 Alarm and Shutdown LEDs

Appl ication NotesMounting Electronic Switches

Outline & Dimensions

Wiring Diagram


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1.0 General Description

1.1 Introduction

The single set point model contains one trip limit for shutdown. The optional dual set point model containstwo independent trip limits; one for alarm and one for shutdown. Shutdown and Alarm trip is set in velocity.In addition, a 4-20 mA output proportional to vibration level is provided.

The 440 and 450 performance, wiring, and specifications are identical except for the enclosure. The 440

meets NEMA 3, 4 and 12. The 450 meets these and certain explosion proof specifications.

1.2 Protection of Rotating and Reciprocating Machinery

a) A system is required which is responsive to faults which:

1) present themselves as low frequency vibrations such as imbalance, misalignments, defective sleeve bear-ings, broken tie down bolts, etc.

2) present themselves as higher frequency vibrations such as defective ball or roller bearings, gear mesh,blade pass frequencies, and in the case of reciprocating machinery, detonation and broken parts.

Velocity is the optimum parameter for both high and low frequencies, since it is equally sensitive to both.Acceleration (as with mechanical switches) is over sensitive to the high frequencies and very insensitive tothe low frequencies.

b) Time delay is absolutely essential in any usable vibration monitor. Virtually all machines will exhibit highvibration for several seconds during startup. If time delay is not provided, the operator must turn up the trippoint to get thru startup. The resultant setting will be too high to provide protection during normal running.This is one reason there are so many cases where machines with mechanical type vibration switches havenot tripped. Time delay is included in the Solid State Model 440.

1.3 Summary of Capabilities

Refer to section 1.4

a) Trip is based on vibration severity. The internal sensor (unless the external sensor option has been pur-

chased) is a piezoelectric crystal with built-in microelectronics to reduce noise sensitivity. The output signalis electronically integrated to measure and trip on velocity or displacement.

b) Calibrated set point controls permit adjusting set points to known values of vibration level. Shutdown andAlarm set point range is in velocity.

c) 4-20 mA output provides continuous monitoring capability on a millimeter or a programmable controller fordata logging or alarm. The 4 mA will be present even when there is no vibration, thus demonstrating the unitis functioning. 4mA =No Vibration and 20mA Full Scale.

d) A solid-state relay (triac) is provided with contacts that are optically isolated from the input power. Theoptional dual set point has two triacs. Each triac is independently settable for open on alarm or close onalarm. Optional analog switches or mechanical relays are available.

e) Adjustable (2-15 seconds) time delay is standard. This prevents false tripping on high startup vibrationsand also from non-repetitive transient events.


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f) Self test and calibration.A light adjacent to the set point control comes on the instant the measured vibration level exceeds the setpoint. The unit can be periodically calibrated on line, by turning the set point control down until the lightcomes on. This setting is then compared with the vibration measured with a portable vibration meter, thusproviding a calibration check of the unit. If this setting is maintained, trip will occur after the duration of thetime delay.

1.4 PANEL CONTROL

Calibrated set point controls en-able operator to set specificvelocity trip points.

Light comes on immediately when vibration ex-ceeds set point (alarm or shutdown will trip after 3

second time delay).

Adjustable time delay of 2-15 seconds.Factory set at 3 seconds.

Test position sets in minimum set point so that any vibration will cause trip condition. Light will comeon immediately, and trip will occur after duration of the time delay, proving that the complete systemis operational. If test position is maintained for less than the duration of the time delay, trip will notoccur, thus permitting system test without shutdown.

VDE approved terminal stripaccepts #12 wire. Screw ad-justable clamping yoke ratherthan screw terminal permitseasy, vibration proof connec-

tion. All hardware is captive.

The triac or analog switch isindependently field settable to

open on alarm (N.C.) or closeon alarm (N.O.)


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SPECIFICATIONS

No. of Trips: 440DR:TWO: One for alarm and one for shutdown. Shutdown set in in/sec (velocity model).

Analog Output for Trend ing and Remote Indication: 440SR & 440DR: 10% accuracy over 4-20 mA DC range.Absolute Option: 4 mA =0 vibration; 20 mA =Full scale range of switch. Termination load resistance, less than 450ohms.

Velocit y Set Point: 0.1 to 1.5 in in/sec or 0.2 to 3 in/sec peak. Metric ranges: 3 to 40 mm/sec or 6 to 80 mm/sec

peak

Frequency Range: 2 to 1000 Hz

Time Delay: Field adjustable 2-15 sec. Factory set for 3 sec unless specified otherwise.

Alarm or Shutdown Output (s): Solid state relay (triac). Two in 440DR. Isolated (dry) contact. Each triac fieldsettable for close on alarm (N.O.) or open on alarm (N.C.). 5A continuous, 100A for 10 msec. Max. off-state leakagecurrent: 1 Ma Min holding current: 50 mA typical Max. voltage across SS relay: 140VAC (280VAC on 230V inputunits). NOTE: If the relay output is connecting to a PLC or DCS, DO NOT use 5A Triac. See How To Select D & E.

Remote Reset: Connection between terminals 5 and 6 latches triac output in alarm state after set point is exceeded.Opening the connection will reset the output to non-alarm state.

Set Point Accuracy: 10% of setting with repeatability of 2%. Circuitry utilizes RMS detector

Vibration Sensitive Axis: Perpendicular to base. Unit can be mounted in any orientation without affecting setting

Temperature Limits : -20F to +140F (-30C to +60C) including internal transducer. -65F to +190F (-55C to+88C) for optional external transducer.

Humidity: 1% to 100% (non-condensing)

Input Power: 100-130 VAC 50/60 Hz standard. 200-260 VAC 50/60 Hz optional. DC input power optional.

Enclosure: Rugged, water-tight, dust-tight, cast aluminum. Meets NEMA, 3, 4 and 12 standards. Optional CSAmark for Class I, Div 2, Grps B-D, Or explosion proof

Model 450. 440 - NEMA 4X

Weight: 440 - 1.6 kg (3.5 lbs); 450 - 2.72 kg (6 lbs)

Mounting: 1/4" hardware, 3 mounting bosses

Terminals: All terminals will accept #12 AWG wire in clamping type yoke without need for termination hardware.ALL hardware is captive.

Self Test:Test position on set point control and light emitting diode provide functional test of trip circuitry, time delayand triac closure. Also permits on-line calibration of switch.

Circuitry: Proprietary hybrid circuitry throughout for minimum size and maximum reliability in vibration environment.

Remote Transducer Option:The standard 440 includes a built-in transducer. A separate transducer can be speci-fied. Please request separate transducer when placing order. See How To Select page. The SA6200A accelerome-ter (100 mV/g) is recommended.


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Analog switch option:Recommended in place of triac for DC operation or light loads such as computer or PLCs.AC/DC Solid-StateContacts are optically isolated from input power.Field settable N.O. or N.C.170 mA continuousMaximum off state leakage, 10 micro ampsNo holding current requiredMaximum voltage: 250 V

Mechanical relay option:SPDT Version: 8 amp at 250 VAC or 24 VDC

DPDT Version: 1. DPDT, 2 amp each half at 250 VAC or 24 VDC2. SPDT, 8 amp each half at 250 VAC or 24 VDC

The N.O./N.C. slide switch are not available on the mechanical relay versions.

Additional environment specifications:

Operating Altitude: up to 2000 metersMain voltage fluctuation: up to 10%Approvals: CSA General Safety

CSA Class I Hazardous Environments

1.6 Safety Warning

CAUTION - SHOCK HAZARD 230/110 VOLTS

The terminal block inside the 440 is connected to AC power (110 VAC or 230 VAC depending on model) except DCinput power models.

If adjustments to the device are being made with power applied, exercise caution to avoid contact with the terminalblock screws by any part of the body or electrically conductive tool.

EQUIPMENT OPERATION

Note that if the 440 vibration switch is used in a manner not specified by the manufacturer, the protection providedby the unit may be impaired.


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2.0 Mechanical Installation

Refer to reference drawings.

2.1 Orientation

The sensitive vibration measuring axis is perpendicular to the base of the unit (vibration switch or trans-ducer). Always mount the unit such that the desired vibration of the equipment being monitored will occuralong this axis.

2.2 Mounting Surface

Choose or fabricate a solid (rigid) surface (on the equipment being monitored) to mount the vibration switchor transducer. This will ensure transfer of the vibration to the vibration transducer, while not introducing spu-rious vibrations.

In addition, the surface presented to the base of the unit should be flat. Fasten using sturdy hardware at allplaces provided.

2.3 Temperature considerations

The switch is designed to dissipate internal heat by conduction through its base. Hence, it is important tokeep the mounting surface below the switch max temperature limit of 140F. If the equipment being moni-tored is going to exceed this limit, consideration should be given to either using one of the remote transduc-ers, or thermally isolating the switch.

To ensure accurate switch performance, a warm-up time of 5 minutes is recommended.

2.4 Cable/Wiring

The method chosen to electrically connect to the switch or transducer should be mechanically flexible, toeliminate the measurement of vibration of material not of interest (piping, etc.), and provide a moisture bar-rier as well.

Although seal tight and other flexible conduit have been used successfully, in areas of extreme humidity ormoisture it is recommended that an SO type cable together with a suitable rain-tight CGB fitting be used.

No stress should be possible on the wiring to the terminal block. If such protection is not provided by theconduit system, some form of stress relief must be installed where the wiring exits the 440.

To assure compatibility with EMC standards, any signal level wiring such as transducer, reset, lockout, or4-20 mA wiring should utilize shielded cable in EMI proof conduit, separate from any power wiring. The sig-nal conduit and power-wiring conduit can be connected at the 440-cable entry via a T fitting.

2.5 Sealing

In 440 installations where temperature and humidity conditions vary around the dew point, it is important thatthe cover plate be evenly and firmly fastened down with the four screws provided.

Although the switch enclosures meet NEMA standards for water tightness, it will do no good if proper sealingof both cover and wiring entrances are not followed. Please remember that a hollow pipe through whichwires may enter a switch may conduct moisture as well.

3.0 Electrical Wiring

3.1 Wiring to the Vibration Switch

The following sections refer to the wiring diagrams at the end of section 3.


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3.1.1 Input Power

Connect a grounding wire to the grounding screw provided in the switch. This is important for safety as wellas noise. For AC powered units, power only with the voltage level indicated on the inner cover label. Orien-tation of AC power to terminals 1 and 2 is not important. For DC powered units, connect +24V to Pin 1 andGround to Pin 2.

3.1.2 Shutdown Circuit

The internal shutdown switch circuit is designed to be wired in series with the external shutdown circuit i.e.;motor starter, relay, contactor, etc. Maximum ratings are found in section 3.2.1. Also see section 3.2.2.

3.1.3 Remote Reset

Shielded wire is required. To avoid creating ground loops, the N.C. remote switch contacts should be elec-trically isolated from other circuits or grounds. NOTE: Remote reset is disabled if pushbutton reset option isselected.

3.1.4 Lockout (Optional)

Terminal 7 will be labeled Lockout. Shielded wire is recommended. To avoid the possibility of groundloops, the remote N.O. lockout switch contacts should be electrically isolated from other external circuitry orgrounds. See section 3.2.4 for further information.

3.1.5 4-20 mA Analog Output

To avoid the possibility of ground loops, the 4-20 mA remote meter terminals should be electrically isolatedfrom external grounds. Shielded wire is recommended to protect against damage due to long wire runs andthe possibility of high induced voltage spikes from storms, etc. See section 3.2.5. The 4-20 mA output isself-powered and therefore requires no external power source.

3.1.6 Alarm Circuits

The internal single pole solid state switch between terminals 13 and 14 is designed to be wired in series withthe external alarm circuit i.e.; annunciator, lamp, relay, etc. Maximum ratings are found in section 3.2.1.Also see section 3.2.2.


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3.2 Functional Description and Installation Considerations

3.2.1. Alarm or Shutdown

3.2.1.1 Units with Triacs (identi fied by Model No. 440DR-2X01-XXXX)

Maximum ratings for the solid state relays used for alarm and shutdown are as follows:

Continuous current 5 A

Surge & Overload (Duty cycle less than 1%)1 second 25 A16 Millisecond 50 A1 Millisecond 125 AMaximum voltage 140 VAC (115V Model)

280 VAC (230V Model)Maximum off state leakage 1 mAIsolation 2500 VAC minRequired holding current 50 mA

As you can see from the above specs, these are medium power rated devices and are quite useful in con-trolling relays, contactors and most motor starters directly. Maximum noise immunity is obtained when usedin the open on alarm (N.C.) mode.

3.2.1.2 Unit s with Analog Switch in p lace of Triac (identifi ed by Model NO. 440DR 2X22-XXXX)

For light loads such as computers or PLCs, the analog switch is easier to interface since it has virtually noleakage current. The analog switch does not require the 50 mA holding current and operates equally wellwith AC or DC.

Maximum ratings are as follows:

Continuous current 170 mAMaximum voltage 250VMaximum off state leakage 10 Micro ampRequired holding current NoneIsolation 2500V

3.2.2 Open/Close on Alarm

The alarm and shutdown triacs (or analog switches) are independently field settable for N.O. (close onalarm) or N.C. (open on alarm). The switches are accessible with a non-conductive screwdriver via the innerside panels.

Open on alarm is recommended in installations where triac lines are likely to be noisy, i.e.: large transientvoltage spikes due to unsuppressed relay, solenoid, or other inductive loads.

3.2.3.1 Auto Reset Mode

In this mode, alarm and shutdown switches are automatically reset to the non-alarm condition when the vi-

bration level falls below the set point.

3.2.3.2 Latch Mode

In this mode, alarm and shutdown switches remain latched in alarm (shutdown) condition when the vibra-tion level exceeds the set point for the duration of the time delay. The unit is in this condition when the re-set terminal is connected to common.


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3.2.3.3 Remote Reset Mode

When wired in this mode, the alarm and shutdown switches latch in trip, but can be reset to the non-alarmmode by momentarily interrupting the connection from terminal Reset to Common. This can be accom-plished with a normally closed momentary switch. The switch contacts should be isolated from other cir-cuits, potentials or grounds. NOTE: Remote reset is disabled if pushbutton reset option is selected.

3.2.4 20 Second Lockout (optional)

With this option, the shutdown and/or alarm triacs will not be permitted to actuate for 20 seconds after Lockout is connected to Common.

3.2.5 4-20 mA Output

This self-powered loop provides a 4-20 mA output current proportional to vibration.

For absolute option, 4mA =0 vibration, 20mA =full scale of the switches vibration range.

3.3 Special Considerations

3.3.1 Light Loads

The solid state triacs used in the standard 440 series are a special high transient immunity, medium powertype. Off state leakage is 1 mA max and should not create any problems, even when interfaced with a loadas light as a programmable controller.

Minimum load required to keep the triac on is 20 mA typical and 50 mA max due to the holding currentspecifications. If the load is less than this, a resistor may have to be placed in parallel with the load, i.e.; for115 VAC light load (50 mA or less) a 2K-ohm 10 watt power resistor is recommended.

3.3.2 D.C. Loads with tr iacs

Although most applications use AC input power and AC on the triac outputs (alarm and shutdown), thesetriacs may be used in DC applications providing minimum loading requirements are met. See section 3.3.1.When DC is used, a triac will automatically latch in the on condition after trip, thus only close onalarm (N.O.) can be used. To reset an external reset switch, the rest switch must be wired in series with the

load.

To avoid large voltage drops during DC operation, the triac should be connected as follows:

Shutdown: Term 4 POS Alarm: Term 14 POSTerm 3 NEG Term 13 NEG

3.3.3 120 mA Analog Switch Opt ion

The special requirements of sections 3.3.1 and 3.3.2 do not apply. However, maximum current is limited to170 mA. (See section 3.2.1.2).


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4.0 CONTROL SETTINGS

4.1 Setting Trip Points

The Model 440DR provides two trips: one for alarm and one for shutdown.

The first trip (alarm) is set at a vibration alarm level to provide early warning that the condition of the machine is deteriorating. If the machine condition continues to deteriorate, the shutdown trip provides protecttion against catastrophic failure.

The shutdown and alarm is set directly in inches/seconds or mm/sec.

The following will help assist you in determining the proper set point.

1. The Warning Level Guide shown below indicates recommended starting points for vibration warning lev-els, defined as levels at which abnormal wear is occurring. Vibration analysis is recommended at this level.Different warning levels are given for different types of machinery.

2. These ranges are typical. Each machine will have its own personality, depending on how it is loaded, theparticular installation, and the tolerances of the machine itself. Thus, you must make the final judgment foryour equipment.

Determine Vibration Warning Levels


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4.2 Setting of Time Delay

An important feature of PMC/BETA switches is the built-in time delay. This prevents triggering of the alarmor shutdown functions from transient increases in vibration levels. It also avoids shutdown due to transitoryvibrations occurring during start-up.

The time delay is adjustable. It will have been set at the factory for three (3) seconds unless your orderspecified otherwise.

The time a vibration must be above set point before trip occurs is individually adjustable for shutdown andalarm from 2 to 15 seconds.

To readjust the time delay, turn the shutdown set point (or alarm set point for alarm time delay) knob CCWuntil the LED illuminates. The time from this point to relay actuation is the time delay. Change the time de-lay via a nylon non-conductive screwdriver. Set CW to increase time delay (one complete turn is approxi-mately 0.5 seconds). Then recheck and readjust until the desired time delay is achieved.

4.3 Test Mode

The test position of both shutdown and alarm knobs is used to test the switch functions without the need forvibration. When the shutdown knob is turned to test, the shutdown LED should immediately illuminate, the4-20 mA should exceed 20 mA, followed after the delay time by actuation of the shutdown relay. Alarm issimilar, but has no effect on the 4-20 mA out.

If the shutdown or alarm knob is returned to a normal setting before the duration of the time delay has beenexceeded, the LED will come on without energizing the triac.

4.4 Alarm and Shutdown Light Emitting Diodes

Since the LEDs activate instantaneously (before time delay), they can be used to check the machines actualvibration level, i.e.; slowly decrease shutdown set point by turning the set point knob counter-clockwise untilthe shutdown LED illuminates. Note this setting and return the knob to a higher setting (before time delayruns out). This is the actual vibration level present.

5.0 System Block Diagram

An internal transducer module consisting of a crystal assembly and integral charge amplifier senses vibrat-ion. Thus, the electrical output of the transducer is a well buffered (low impedance) signal directly propor-tional to acceleration (G) of the switch.

The signal goes to a custom hybrid circuit to yield an A.C. signal now proportional to velocity. This signal inturn is routed through an amplifier, the gain of which is controlled by the shutdown setpoint.

Next, the signal is processed through a true RMS to DC stage and compared against a preset internal voltage reference. If the signal level is higher than reference, the shutdown LED is illuminated.

If the voltage level stays above the reference for the duration of the time delay, an output trip occurs and theshutdown solid-state relay will trip.

Alarm trip is derived in much the same manner, branching from the output of the RMS to DC stage. Likewisethe DC output is directed to the voltage to current hybrid.


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Appl ication Note

Mounting Electronic Vibration Switches

Where To Mount The Switch

It is desirable to mount the electronic switch (or transducers for remote monitoring systems) on the bearinghousing, since the forces on the rotating member (unbalance, misalignments, bearing wear, aerodynamics,etc.) reach the outside world through the bearings.

Most bearing housings are curved so it is necessary to attach a bracket with a flat surface for mounting theswitch. If the machine has bolted end plates on the bearings or horizontally split bearing housings, thesebolts can be used to attach the bracket.

When bolt holes are not available or are not suitable, an alternative way is to weld an angle iron bracketsimilar to that in the sketch, but oriented so as to straddle the bearing housing similar to:

The best approach is to mount a gusseted bracket.

For most applications 3/8 Inch material (preferably steel) will be suitable.

Sensitive Axis

Please note that the electronic vibration switch can be mounted in any orientation without a change in sensi-tivity. It senses vibration in a direction perpendicular to its mounting surface.


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Choosing Mounting Direction

The vibration switch can be mounted in the vertical or horizontal direction (or anything in between).

The best way to choose the mounting direction is to measure the vibration level in both directions with a vi-bration meter (such as the Metrix 5500) and choose the direction with the highest level. This will usually behorizontal, since the machine structure is usually less rigid horizontally than vertically.

How Many Monitor Points Per Machine

Anywhere from one to four switches are used per machine (depending on how critical the machine is to theprocess or how expensive it is), one on each end of the motor and one on each end of the compressor, fan,pump or whatever is being driven. If there is a gear box in between, one may be used here also.

It is quite common to use only one switch. In this case, it is best to mount on or near the driven bearing. Forexample, if you have a motor and large fan with a bearing on each end of the fan, the fan bearing on themotor side would be the driven bearing. It will usually see the highest forces and have the highest vibrationlevel.

Mounting At Other Locations

It is not always possible to mount on the bearing. The unit can then be mounted on the bearing pedestal oron a structural member nearby. Again, it is desirable to survey the machine with a vibration meter. If thelevel at the intended location is about the same (within 25 or 50%), it probably will be satisfactory. Ofcourse, the trip setting would be reduced if the vibration level at the mounting location is smaller than at thebearing. (See Application Note 803 for information on recommended trigger levels).


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OUTLINE & DIMENSIONS

440 MODEL

101.6 [4.00]9.5 [.37]

88.9 [3.50]

44.5 [1.75]

65.1 [2.56]

3/4-14 NPT

44.5 [1.75]

8.9 [.35]71.1 [2.80]

88.9 [3.50]3X 7.9 [.31]

108 [4.25]

127 [5.00]

SENSITIVE AXIS

450 MODEL

152.4 [6.00]

108 [4.25]

152.4 [6.00]

108 [4.25]

139.7 [5.50]

76.2 [3.00]

3/4-14 NPT76.2 [3.00]

27.9 [1.10]

SENSITIVE

AXIS

4X 7.9 [.312]


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WIRING DIAGRAM(FULLY CONFIGURED)


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WIRING DIAGRAM(FULLY CONFIGURED)


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This electronic equipment was manufactured according to high quality standards toensure safe and reliable operation when used as intended. Due to its nature, thisequipment may contain small quantities of substances known to be hazardous to theenvironment or to human health if released into the environment. For this reason,Waste Electrical and Electronic Equipment (commonly known as WEEE) should neverbe disposed of in the public waste stream. The Crossed-Out Waste Bin label affixed

to this product is a reminder to dispose of this product in accordance with local WEEEregulations. If you have questions about the disposal process, please contact MetrixCustomer Services.

ENVIROMENTAL INFORMATION

Manual Vibration Switch 440 450 Rev f

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